Aqua-Hot HHE-200-08E User manual

Category
Water heaters & boilers
Type
User manual

This manual is also suitable for

SERVICE MANUAL
© 2012 Aqua-Hot Heating Systems Inc.
HHE-200-09E
HHE-500-09M
NOTE: This Service Manual will also work with model numbers:
HHE-200-08E, HHE-500-08M, AHE-450-DE1 and AHE-450-DM1
Page 3
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
Section 1: Introduction to the Hydro-Hot
Introduction ............................................................................................................... ..Page 6-7
Danger, Warning, Caution, and Note Box Definitions ................................................... ...Page 6
Section 2: Hydro-Hot Hydronic Heating System Overview
Technical Information ................................................................................................... ...Page 8
I.D. Label Sample ......................................................................................................... ...Page 9
Component Overview .................................................................................................Page 9-11
Hydro-Hot Operational Flow-Chart ............................................................................. ..Page 12
Antifreeze & Water Heating solution ...................................................................... ..Page 13-14
Section 3: Interior Switch Panel
Diesel-Burner Switch .................................................................................................. .Page 15
Electric Element Switch .............................................................................................. .Page 15
Engine Preheat Switch ............................................................................................... .Page 15
Pin Label ...................................................................................................................... Page 16
Section 4: Hydro-Hot Components
Fluid Level Sensor ................................................................................................ ..Page 17-18
Control Thermostat ...................................................................................................Page 19-20
A.C. High Limit Thermostat .......................................................................................... Page 21
D.C. High Limit Thermostat .......................................................................................... Page 22
Low Temperature Cut-Off Thermostat ......................................................................Page 22-23
Check Valves ...........................................................................................................Page 23-24
Tempering Valve ......................................................................................................Page 25-26
Circulation Pumps 1 & 2 ...........................................................................................Page 27-28
Stir Pump .................................................................................................................Page 29-31
Engine Preheat Pump ..............................................................................................Page 32-34
Electric Heating Element ..........................................................................................Page 35-36
A.C. Relay .................................................................................................................... .Page 37
Section 5: Electronic Controller
General Facts ............................................................................................................... .Page 38
Secondary 12 Volt DC battery Connection ................................................................... .Page 39
Terminal Strips with Screw-Type Fasteners ................................................................. .Page 39
Low Voltage Reset Feature .......................................................................................... .Page 40
Replacement Procedure ............................................................................................... .Page 41
Proper Jumper Pin Formation ...................................................................................... .Page 41
Table of Contents
Page 4
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
Section 6: Electronic Controller Indicator Lights
Electric Heating Element Status Indicator Light ........................................................... Page 42
Heating Zones Status Indicator Lights 1-5 ................................................................... Page 42
Low Battery Voltage Fault Indicator Light ..................................................................... Page 42
Low Temp Cutoff Status Indicator Light ....................................................................... Page 42
Low Tank-Level Cutoff Indicator Light .......................................................................... Page 42
Heating Status Indicator Light ...................................................................................... Page 42
Engine Preheat Pump Indicator Light ..................................................................... Page 42-43
[Circulation] Pump #1 Indicator Light ............................................................................ Page 43
[Circulation] Pump #2 Indicator Light ............................................................................ Page 43
[Stir] Pump #3 Indicator Light ....................................................................................... Page 43
Diesel-Burner Status Indicator Light ............................................................................. Page 43
Overload Fault Indicator Light ...................................................................................... Page 43
Section 7: Diesel-Burner Overview
Overview ...................................................................................................................... Page 44
I.D. Plate ...................................................................................................................... Page 44
Diesel-Burner Overview ............................................................................................... Page 45
Diesel-Burner Operational Flow Chart .......................................................................... Page 45
Diesel-Burner Operational Overview ...................................................................... Page 47-49
Section 8: Detaching and Reattaching the Diesel-Burner
Detaching the Diesel-Burner .................................................................................. Page 50-52
Reattaching the Diesel-Burner ............................................................................... Page 53-55
Section 9: Diesel-Burner Components and Repair Information
Diesel-Burner Component Overview ............................................................................ Page 56
Troubleshooting Flow Chart ................................................................................... Page 57-62
Motor ...................................................................................................................... Page 63-66
Flame Sensor ......................................................................................................... Page 67-68
Ignition Electrodes .................................................................................................. Page 69-70
Fuel Nozzle ............................................................................................................ Page 70-71
Fuel Solenoid ............................................................................................................... Page 72
Fuel Pump .............................................................................................................. Page 73-75
Bearings ................................................................................................................. Page 76-78
Ignition Coil ............................................................................................................ Page 79-80
Controller ................................................................................................................ Page 81-82
Table of Contents
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
Section 10: Troubleshooting
If the Hydro-Hot is Black Smoking ................................................................................ Page 83
If the Hydro-Hot is Blue/White Smoking ....................................................................... Page 84
If one of the Hydro-Hot’s Heating Zones will not get hot .............................................. Page 85
If there is a lack of domestic continuous hot water ....................................................... Page 86
If there is antifreeze leaking ................................................................................... Page 87-88
Appendix A: Wiring Diagram .............................................................................................. Page 89
Appendix B: Fuel Pressure check and Adjustment .....................................................Page 90-93
Appendix C: Extreme Cold Weather Operation ............................................................Page 94-95
Appendix D: Aqua-Hot Annual Maintenance .............................................................. Page 96-110
Appendix E: Winterization Process .................................................................................. Page 111
Appendix F: Filling/Draining the Aqua-Hot ............................................................... Page 112-115
Table of Contents
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 1: INTRODUCTION TO THE HYDRO-HOT
This service manual is designed to aid trained
and qualified service technicians with the pro-
cess of troubleshooting and servicing the Hydro
-Hot Hydronic heating system.
The Hydro-Hot heating system features a 12 Volt-DC pow-
ered diesel-burner and a 120 Volt-AC, 1650 Watt electric
heating element. These two heating sources are used in con-
junction with an FDA-approved “GRAS” (Generally Recog-
nized as Safe) propylene glycol based boiler antifreeze and
water heating solution in order to provide a continuous sup-
ply of domestic hot water, interior/fresh water tank heating,
independent interior zone heating, and engine preheating. Be
sure to reference Figures 3 through 5 for a complete compo-
nent overview.
Please note that all Danger, Warning, Caution, and Note box-
es, appearing as needed throughout this manual, must be
reviewed and adhered to during any service procedure in
order to avoid potential hazards, which could result in injury,
product damage, or property damage.
Should additional assistance be needed, please contact the
technical support department at 1-800-685-4298, Monday
through Friday, between the hours of 7:00 AM and 4:00 PM
Mountain Standard Time.
Danger, Warning, Caution, and Note Boxes:
Danger, Warning, Caution, and Note boxes appear through-
out this manual as a means of alerting the service technician
to important information.
INDICATES THAT PERSONAL INJURY IS LIKELY OR
IMMINENT.
Indicates that serious damage to the heater will occur
and personal injury is possible as well.
Indicates that damage to the heater is possible.
NOTE: Indicates information that requires special atten-
tion by the service technician
Understanding the Hydro-Hot Major Systems:
The basis for the Hydro-Hot heating system’s functionality is
the antifreeze and water heating solution, which is comprised
of water that is distilled, de-ionized, or soft, as well as FDA-
approved “GRAS” propylene glycol based boiler antifreeze.
Through this solution’s ability to maintain and transfer heat,
the Hydro-Hot’s three major systems: the domestic water
system, engine preheat system, and interior heating system,
are able to function effectively. This antifreeze and water
heating solution is contained within the Hydro-Hot’s boiler
tank and is heated by the diesel-burner when its operating
criteria are met and/or the electric heating element when its
operating criteria are met. In order for the diesel-burner to
be considered as a heating source by the Hydro-Hot, it must
have an adequate fuel supply, receive power from the elec-
tronic controller, and be selected as a heating source from the
interior switch panel. In order for the electric heating ele-
ment to be considered as a heating source by the Hydro-Hot,
it must receive power from either a generator or from shore
power and be selected as a heating source from the interior
switch panel. Once the antifreeze and water heating solution
achieves operating temperature (as determined by the Hydro-
Hot’s control thermostat), the domestic water system, the
engine preheat system, and the interior heating system are
permitted to operate as needed.
Domestic Hot Water Priority System:
The Hydro-Hot is a Hot Water Priority System. Meaning,
that the Hydro-Hot cannot heat the interior of the motor
home, and produce continuous hot water simultaneously.
When Domestic Hot Water is being used, the interior heating
system will shut down, until no more Domestic Hot Water is
called for.
The domestic hot water priority system is responsible for
providing hot water whenever a hot water faucet is opened
such as with a shower or sink.
When hot water is requested, domestic water from the motor
home’s fresh water tank is transported through a copper coil
in the Hydro-Hot’s boiler tank where heat is transferred from
the heated antifreeze and water heating solution to the do-
mestic water flowing through the copper coil. The heated
domestic water then flows through the tempering valve to be
mixed with cool water from the fresh water tank to achieve
an appropriate temperature before it flows to the faucet re-
questing hot water.
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 1: INTRODUCTION TO THE HYDRO-HOT
Engine Preheat System:
The engine preheat system is responsible for heating the mo-
tor home’s engine block in order to make it easier to start-up
when cool weather conditions exist.
When the engine preheat system is activated via the interior
switch panel, the motor home’s engine coolant is circulated
through a dedicated copper coil in the Hydro-Hot’s boiler
tank, where heat from the antifreeze and water heating solu-
tion is transferred to the motor home’s engine coolant. The
heated engine coolant is then transported back to the engine
where it transfers the heat to the engine to gradually warm it.
Additionally, the Hydro-Hot includes a Motor-aide feature,
which uses the circulation of the motor home’s engine to
transport the engine’s coolant from the Hydro-Hot’s boiler
tank to the motor home’s warm engine and back to the boiler
tank. Through this process, the boiler tank is kept heated,
which reduces the time required to bring the tank to operat-
ing temperature for interior heat and continuous domestic hot
water. This Motor-aide feature is part of the engine preheat-
ing feature and plumbing system, and requires no action on
the user’s behalf to function.
Interior Heating System:
The interior heating system is responsible for providing heat
to the motor home’s interior in order to maintain the temper-
ature at a comfortable level.
For interior heating, it is the room thermostats that trigger the
Hydro-Hot’s interior heating system. When a thermostat
recognizes that heat is required in a particular area, it sends a
signal to the Hydro-Hot’s electronic controller calling for
heat. The Hydro-Hot responds by activating the circulation
pump for that zone, which sends the heated antifreeze and
water heating solution through the Heating Loop correspond-
ing to the zone requesting heat. The fans on the heat ex-
changers in the zone calling for heat are also activated; there-
fore, as the heated solution flows over the heat exchanger’s
fins, the heat is transferred to those fins and dispersed into
the interior of the motor home by the fans. Until the thermo-
stat signals that heat is no longer required, the Hydro-Hot
will continue to send the heated antifreeze and water solution
through the loop, which returns the cooled solution to the
Hydro-Hot’s boiler tank to be re-heated before being sent
back through the loop again. This process continues until the
pre-set temperature of the interior is reached, and the interior
room thermostat signals the electronic controller that heat is
no longer required.
AC Circuit:
Although the diesel-burner is the primary heating source for
the Aqua-Hot and is necessary for providing continuous do-
mestic hot water, an alternate heat source exists for moderate
temperatures, which functions with an AC circuit. Whenever
the motor home is connected to an AC power source -
plugged into shore power or using a generator, the Hydro-
Hot’s electric heating element has the ability to function in
order to provide heat for the boiler tank.
When the antifreeze and water heating solution falls below
operating temperature (as determined by the control thermo-
stat), a signal is sent to the electronic controller requesting
heat. Because the electric element switch is activated on the
interior switch panel, the DC power from the electronic con-
troller is permitted to flow to the AC relay, which activates
the relay in order to allow AC power to flow to the electric
heating element. When the electric heating element receives
power, it becomes active and supplies heat to the boiler tank
until operating temperature is reached.
NOTE: The Engine Preheat is an option on the Hydro-Hot
Heating system. If you have model number HHE-500-09M,
the heater does not have the engine preheat feature, but it
does have the Motor-Aide feature
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 2: HYDRO-HOT OVERVIEW
Diesel-Burner, Heat Input (Firing Rate) ................................................................................................................................................ 56,000 BTU/hr
Diesel-Burner, Fuel Consumption (Continuous Operation) ...................................................................................................................... 0.40 gal/hr
Heater, Voltage/Maximum Power Consumption .................................................................................................................... 12 Volt-DC/60 watts
Electric Heating Element specifications ................................................................................................................................ 120 Volt-AC/1650 watts
Zone Heat Circulation Pump specifications ................................................................................................................ (2) 12 Volt-DC/21 watts each
Number of Heating Zones ............................................................................................................... maximum of 5, plus Engine Preheat (optional)
Domestic Water Heating Capacity ........................................................................................................................................... continuous/on-demand
Antifreeze Type Used .........................................................
Generally Recognized as Safe by the FDA - Propylene Glycol Boiler
Dimensions .................................................................................................................................................................................... 12”H x 18.5”W x 30”L
Dry Weight ..................................................................................................................................................................................... approximately 127 lbs.
Wet Weight ..................................................................................................................................................................................... approximately 184 lbs.
NOTE: All vehicle installations must comply with the requirements listed in the Recreational Vehicle Industry Association’s
(RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle Standards. To receive a copy of this handbook and other perti-
nent RVIA Standards, write to: Recreation Vehicle Industry Association, 1896 Preston White Drive, P.O. Box 2999, Reston,
VA 22090-0999, call them at (703) 620-6003, or visit them online at www.rvia.org.
Hydro Hot Technical Specifications
Figure 1
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 2: HYDRO-HOT OVERVIEW
Figure 3
Refer to Installation
Manual
Heating Zone
1 Outlet Port Heating Zone
2 Outlet Port Wiring Harness
& Harness Port
Diesel Fuel
Supply and
Return Ports
Diesel
Burner
Zone 2
Circulation
Pump
Zone 1
Circulation
Pump
VAC
Access
Panel
AC
Wiring
Port
Figure 2
Drain
Valve
Assembly
Hydro-Hot
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 2: HYDRO-HOT OVERVIEW
1
2
3
4
5
Figure 4
6
Interior Heating
Return Ports
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 2: HYDRO-HOT OVERVIEW
Figure 5
1
4
2
1
2 5
3
3
5
4
AC Wiring Cable Clamp
Heating Zone Outlet Ports (Supply)
13 LB Radiator Cap
I.D. Label Location
Diesel Fuel Supply/Return Ports
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 2: HYDRO-HOT OVERVIEW
Chart 1
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 2: HYDRO-HOT OVERVIEW
Antifreeze and Water Heating Solution:
As the antifreeze type and mixture ratio is essential to the
Hydro-Hot’s performance and ability to comply with
regulations, the following information is being supplied to
understand various types of antifreeze, the quality of wa-
ter necessary, and the mixture ratio. Hydro-Hot Heating
Systems Inc. recommends CAMCO’s Boiler Antifreeze
-100°.
Antifreeze Types:
The following information addresses the necessary usage of
a propylene glycol based “boiler type antifreeze in the Hy-
dro-Hot. Propylene glycol is a safer alternative to the more
toxic ethylene glycol antifreeze; however, as mandated by
IAPMO (International Association of Plumbing and Mechan-
ical Officials), only those propylene glycol based “boiler”
type antifreezes deemed “Generally Recognized as
Safe” (GRAS) by the FDA should be utilized.
Because of the significant impact various types of antifreeze
can have on a Hydronic heating system, including the level
of safety provided, it has been recognized that there is a need
to provide an explanation regarding two additional promi-
nent types of antifreeze/coolant available. The following
information should be utilized as an educational means of
ensuring that the proper type of propylene glycol based anti-
freeze is selected:
RV & Marine Antifreeze:
These types of propylene glycol based antifreeze products
are formulated specifically for “winterizing” applications
only. Although RV & Marine antifreeze is often “Generally
Recognized as Safe” by the FDA, it should never be used in
the Hydro-Hot’s Hydronic Heating System. This type of
antifreeze is not formulated to transfer heat, which is essen-
tial to the heating system’s functionality and does not contain
rust inhibitors. Please note, however, that RV & Marine
antifreeze can be utilized to winterize the Hydro-Hot’s do-
mestic water heating system.
Automotive Antifreeze/Coolant:
These types of propylene glycol based antifreeze products
are formulated specifically to protect automotive engines
against corrosion, freezing temperatures, and overheating.
They also have excellent heat transfer and thermal conduc-
tivity characteristics. Although these types of antifreeze
products are considered less toxic and safer than ethylene
glycol for people, pets, and the environment, they are not
“Generally Recognized as Safe” (GRAS) rated by the FDA.
Therefore, they must be marked with a “harmful if swal-
lowed” warning. This additional warning is required be-
cause these types of antifreeze products contain high levels
of chemical inhibitors. Due to their potentially hazardous
properties, they should never be used in the Hydro-Hot’s
Hydronic Heating System.
Antifreeze Mixture Water Quality:
In order to ensure maximum performance and longevity of
an Hydro-Hot heating system’s boiler tank and associated
components, it has been determined that there is a need to
use distilled, de-ionized, or soft water in combination with
concentrated Ethylene glycol for the Hydro-Hot’s antifreeze
and water heating solution,. Please note that this is only nec-
essary when mixing concentrated Ethylene glycol antifreeze
with water; suppliers of pre-mixed antifreeze are responsible
for the use of high-quality (distilled, de-ionized, or soft) wa-
ter when preparing their antifreeze for sale.
Hard water possesses a high-level of calcium and magnesium
ions, which deplete the propylene glycol antifreeze’s corro-
sion inhibitors. This, in turn, causes the antifreeze and water
heating solution to begin turning acidic, which can corrode
the Hydro-Hot’s boiler tank and associated components
prematurely. Therefore, concentrated propylene glycol
should be diluted with distilled, de-ionized, or soft water that
is 80 PPM or less in total hardness. The local water agency
should have up-to-date water quality reports that should indi-
cate if the local tap water is within this guideline.
Antifreeze Terms and Mixture Ratio:
The following information addresses the process of selecting
an antifreeze and water mixture ratio that provides adequate
freeze, boiling, and rust/anti-corrosive protection. A 50/50
mixture of propylene glycol / water ratio is recommended,
which will result in a freeze point of approximately -28°F
and a boil point of approximately 222°F.
The following information should be utilized for the purpose
of clarifying some terms commonly associated with anti-
freeze.
Page 14
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
Freeze Point and Burst Point:
Antifreeze lowers the freezing point of any liquid, to which it
has been added, by preventing the formation of ice crystals;
however, as the ambient temperature continues to decline, the
water in the solution will attempt to attain a solid state. The
point in which the water begins to solidify is termed the
“Freeze Point.” Although the water in the solution has begun
to freeze, producing a “slushy” consistency, the antifreeze in
the solution will continue to combat the normal expansion of
the solution as it freezes. The point in which the solution can
begin to expand, due to colder temperatures, is called the
“burst point.” Once the solution reaches the burst point, the
potential is present for ruptured pipes to exist. The burst point
of the antifreeze and water heating solution is dependent upon
the brand of propylene glycol employed.
Boiling Point:
The Hydro-Hot utilizes the antifreeze and water heating solu-
tion as a transportation means for the heat produced from the
internal processes. The antifreeze absorbs the heat created
until its boiling point is reached; it is at this point that the liq-
uid turns to a gas and is expelled to prevent the heating system
from overheating. Each time the boiling point is reached, a
loss of efficiency occurs because the heat produced is expelled
rather than used for the function of the heating system. There-
fore, a higher boiling point is desired in order to combat the
loss of efficiency, which allows the antifreeze to transport the
heat created from the internal process throughout the motor
home where it can be used productively rather than dissipating
due to its change from a liquid to a gas.
Rust and Anti-Corrosive Inhibitors:
Another major function of antifreeze is to provide protection to
the internal metal components of the Hydro-Hot Hydronic heat-
ing system from corrosion and rust. Antifreeze is able to per-
form this function by the addition of rust- and anti-corrosive
inhibitors, which are designed specifically to activate in a water
solution.
Summary:
Antifreeze has three basic functions: freeze protection, boil-
over protection, and anti-corrosion and rust protection.
Antifreeze is also primarily responsible for heat transfer charac-
teristics. Therefore, as water is an excellent heat conductor, it is
added to the mixture. A 50/50 solution of propylene glycol an-
tifreeze and water is recommended to provide the best perfor-
mance combination of the aforementioned functions. If excess
propylene glycol exists within an antifreeze and water heating
solution, the water’s heat absorption properties are compro-
mised, which could ultimately inhibit the Hydro-Hot from
providing adequate domestic hot water and interior heating.
Additionally, if the antifreeze and water heating solution con-
tains over 70 percent antifreeze, the freezing point is actually
raised, resulting in less freeze protection.
SECTION 2: HYDRO-HOT OVERVIEW
Antifreeze and Water Heating Solution: (continued)
Page 15
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 3: INTERIOR SWITCH PANEL
The interior switch panel is used to control the two potential
heating sources for the Hydro-Hot’s boiler tank, as well as to
control the engine preheat feature. When a switch is activat-
ed, the indicator light on the switch will illuminate.
Diesel-Burner Switch:
When the diesel-burner switch is in the on position, any time
the control thermostat tells the electronic controller that heat
is needed for the boiler tank, the diesel-burner will respond
by firing up and providing heat. A cold boiler tank can ex-
pect to be brought to operating temperature by the diesel-
burner in approximately 10 to 20 minutes. In order to obtain
continuous hot water, the diesel-burner switch must be acti-
vated.
Additionally, the diesel-burner switch can be used to reset a
low-voltage condition. This is accomplished by turning off
the diesel-burner switch for 30 seconds, then turning it back
on.
Electric Element Switch:
When the motor home is plugged into an AC power source
(e.g., shore power, generator, etc.) and the electric element
switch is on, the electric heating element will be used to pro-
vide heat to the boiler tank if the need arises. A cold boiler
tank can expect to be brought to operating temperature by the
electric heating element in approximately 1 to 2 hours. The
electric element, alone, will not be able to provide continu-
ous hot water.
Engine Preheat Switch:
The engine preheat switch activates the engine preheat
pump, which draws the motor home’s engine coolant
through the boiler tank to heat it before returning it to the
engine block to transfer the heat there. Either the diesel-
burner switch or the electric element switch must also be
activated in order for the engine preheat feature to function.
The engine preheat switch does not need to be activated for
the motor-aide feature to work and should be shut off when
traveling.
NOTE: If the diesel-burner fails to ignite, the diesel burner
status light will go out, indicating to the customer the burn-
er has gone into a default. To reset the default, the diesel
burner switch must be turned off for 5 seconds and then
turned back on.
Figure 6
NOTE: The Engine Preheat is an option on the Hydro-Hot
Heating system. If you have model number HHE-500-09M
the heater does not have the engine preheat feature, but it
does have the Motor-Aide feature.
Current
Switches
Original
Switches
Discontinued
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© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 3: INTERIOR SWITCH PANEL
Figure 7
Discontinued Switches
Current Replacement Switches
Page 17
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 4: HYDRO-HOT COMPONENTS
Fluid-Level Sensor:
The fluid-level sensor monitors the level of antifreeze and
water heating solution within the Hydro-Hot’s boiler tank to
ensure that an adequate volume exists.
Troubleshoot the fluid-level sensor if one of the following
conditions has occurred:
The diesel-burner and/or electric heating element fails to
operate.
The Hydro-Hot fails to operate and the “Low Tank-
Level Cutoff” indicator light on the electronic controller
is illuminated.
Troubleshooting:
1. Verify that the Hydro-Hot’s boiler tank is full of the
antifreeze and water heating solution.
2. Verify that the harness wire connectors are securely
plugged into the fluid-level sensor.
3. Verify that the fluid-level sensor’s wires are securely
installed in the terminal strip on the wire harness, as well
as tightly fastened to the electronic controller.
4. Verify the functionality of the fluid-level sensor by com-
pleting the following:
A. Remove the faceplate from the electronic controller.
B. Install a jumper wire on the JP3 plug, between pins
15 and 16 (between “LWCO-I” and “LWCO-O”) on
the electronic controller in order to bypass the fluid-
level sensor.
If the “Low Tank-Level Cutoff” indicator light on
the electronic controller extinguishes when the
jumper wire is installed, inspect the wire harness for
damaged or severed wires. If no wires are found to
be damaged or severed, follow the instructions in
this section to replace the fluid-level sensor.
If, however, the “Low Tank-Level Cutoff” indicator
light continues to illuminate once the jumper wire is
installed, follow the instructions in this manual to
replace the electronic controller.
Replacement Procedure:
FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR
TO ALLOW THE HEATER TO COOL BEFORE SERVICING
COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY.
1. Ensure that the Hydro-Hot has been completely shut
down and that all power sources have been disconnect-
ed. Also, because this replacement procedure will
involve the boiler tank and the potential for hot coolant,
be sure the heater has adequately cooled.
2. Drain the antifreeze and water heating solution from the
Hydro-Hot’s boiler tank using the drain valve, Approxi-
mately 1-2 gallons will need to be drained..
3. Disconnect the Fluid Level Sensor’s wires by separating
the quick-disconnect terminals.
4. Using a 7/8 socket, remove the defective Fluid Level
Sensor from the Hydro-Hot’s boiler tank.
5. Wrap the threads of the replacement Fluid Level Sensor
with a thread seal tape.
6. Screw the replacement Fluid Level Sensor into the port
on the Hydro-Hot’s boiler tank and tighten securely with
a 7/8 socket, ensuring the N.O. stamp in on top.
7. Connect the replacement Fluid Level Sensor’s wires in
the same configuration as the removed Fluid Level Sen-
sors wires.
8. Refill the Hydro-Hot’s Boiler tank with the proper
water/antifreeze mixture. Reference Section 5 in this
manual for instructions on filling and draining the
Hydro-Hot unit.
9. Test for proper operation.
Be sure to install the replacement float switch with
the “N.O.” stamp on top, failure to do so, will allow
the diesel/electric to come on with no antifreeze in
the boiler tank.
Page 18
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 4: HYDRO-HOT COMPONENTS
Thermostats
Control Thermostat:
The control thermostat is installed into the Hydro-Hot’s boil-
er tank and monitors the temperature of the antifreeze and
water heating solution to determine when it is at operating
temperature and when it requires heat. The Hydro-Hot is
considered to be at operating temperature between 158°F and
190°F.
Troubleshoot the control thermostat if one of the following
conditions has occurred:
There is a lack of hot domestic water and interior heat.
The heating Status light does not illuminate on the elec-
tronic controller, when the Hydro-Hot is below 158° F.
Excessive Blue or white smoke is expelled from the ex-
haust.
Troubleshooting:
1. Turn the diesel-burner and electric element switches on
the interior switch panel on and check the electronic
controller to ensure that the “Electric Heating Element
Status” and “Diesel-Burner Status” indicator lights are
illuminated.
2. Verify that the “Heating Status” indicator light on the
electronic controller is illuminated as it should be when-
ever the Hydro-Hot is below the operating temperature
range of 158°F.
If the “Heating Status” indicator light is not illuminated,
check the following:
A. Verify that the temperature of the boiler tank has
fallen below the 158°F minimum operating temper-
ature by checking with a digital thermometer.
B. Disconnect the control thermostat’s wires from their
connections, and, using an ohmmeter, check for
continuity.
If there is no continuity, follow the instructions in
this section for replacing the control thermostat.
If continuity exists, complete the following:
a. Inspect the control thermostat’s wiring and
connections.
b. Install a jumper wire on the JP3 plug, between
pins 13 and 14 (“TSTAT-I” and “TSTAT-O”)
on the electronic controller in order to bypass
the control thermostat.
NOTE: The diesel-burner and/or electric element switch
must be in the on position also for the “Heating Sta-
tus” indicator light on the electronic controller to
illuminate.
If the “Heating Status” indicator light on the elec-
tronic controller does not illuminate with the jumper
wire installed, follow the instructions in this manual
to replace the electronic controller.
Figure 8
Page 19
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 4: HYDRO-HOT COMPONENTS
If the “Heating Status” indicator light is illuminated, But
the diesel burner fails to come on: check the following:
1. Verify the diesel burner’s control thermostat wires
are properly connected, and that there are no loose
wires, both at the diesel burner and at the JP4 plug,
on the Electronic Controller.
2. Using a DC Voltmeter Verify both the
C1 (Orange - #22)and the C7 (White - #23) Wires,
on the Electronic Controller’s JP4 Plug have
12VDC.
If the C7 (White - #23) Wire does not have 12VDC, and
both the Diesel Burner Status Light and the Heating Sta-
tus lights are illuminated, the electronic controller will
need to be replaced.
If the C1 (Orange - #22) wire does not have 12VDC Re-
fer to the Webasto Diesel Burner Controller Trouble-
shooting, in section 9.
Control Thermostat Replacement Procedure:
FAILURE TO DISCONNECT ALL POWER SUPLIES AND/OR TO
ALLOW THE HEATER TO COOL BEFORE SERVICING COULD
CAUSE SERIOUS DAMAGE OR PERSONAL INJURY.
1. Ensure that the Hydro-Hot has been completely shut
down and that all power sources have been disconnect-
ed. Also, because this replacement procedure will in-
volve the boiler tank and the potential for hot coolant, be
sure the heater has adequately cooled.
2. Drain the antifreeze and water heating solution from the
Hydro-Hot’s boiler tank using the drain valve.
3. Disconnect the defective control thermostat’s wires by
separating the quick-disconnect terminals.
4. Using a 7/8 socket, unscrew the control thermostat from
the Hydro-Hot’s boiler tank.
5. Wrap the threads of the replacement control thermostat
with Teflon tape.
6. Screw the replacement control thermostat into the port
on the Hydro-Hot’s boiler tank and tighten securely with
a 7/8 socket.
7. Connect the replacement control thermostat’s wires in
the same configuration as the removed control thermo-
stat’s wires.
8. Refill the Hydro-Hot’s boiler tank with the antifreeze
and water heating solution.
9. Test the Hydro-Hot for normal operation.
Figure 9
190 º Control Thermostat
Page 20
© April 2012 Hydro-Hot Hydronic Heating System Service Manual—Rev. A
SECTION 4: HYDRO-HOT COMPONENTS
AC High-Limit Thermostat:
The AC high-limit thermostat serves as a safety measure in
the event that the electric heating element continues to oper-
ate after the maximum operating temperature is reached.
The high-limit thermostat allows the current for the heating
element to pass through it until the boiler tank reaches a tem-
perature of 220°F. Should this temperature be reached, the
high-limit thermostat blocks the current to the element,
which prevents it from continuing to provide heat to the boil-
er tank.
Troubleshoot the AC high-limit thermostat if the following
condition has occurred:
The electric heating element fails to operate.
Troubleshooting:
1. Disconnect all power supplies.
2. Remove the AC access cover.
3. Verify that the boiler tank’s temperature is below 220°F.
4. Locate the AC high-limit thermostat and remove its
wires.
5. Using an ohmmeter, check the thermostat for continuity.
If there is no continuity, press the white reset button on
the thermostat and re-check for continuity.
If continuity is still not present after the reset button has
been pressed, follow the instructions in this section to
replace the AC high-limit thermostat.
Replacement Procedure:
FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR
TO ALLOW THE HEATER TO COOL BEFORE SERVICING
COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY.
1. Ensure that the Hydro-Hot has been completely shut
down and that all power supplies have been disconnect-
ed.
2. Remove the AC access cover.
3. If applicable, remove the heat shrink insulation covering
the wires and terminals on the defective high-limit ther-
mostat.
4. Disconnect the High Limit Thermostat from the A.C.
Relay and the Electric Heating element by removing the
screws securing them in place.
5. Using a 5/8 wrench or socket, remove the defective high
-limit thermostat from the Hydro-Hot’s boiler tank.
6. Install the replacement high-limit thermostat into the
port on the Hydro-Hot’s boiler tank and finger-tighten
only (15 in/lbs).
7. Connect the wires previously removed from the A.C.
Relay and Electric Heating Element
8. Secure the AC access cover back into place.
9. Test for proper operation.
Figure 10
NOTE: If the High-Limit Thermostat is tripped, it is recom-
mended to test the control thermostat, for proper operation
and verify the boiler tank is full of antifreeze.
A.C. High Limit Thermostat
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Aqua-Hot HHE-200-08E User manual

Category
Water heaters & boilers
Type
User manual
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